Awards ceremony
European Business
Awards for the


DBU Innovation award


Cold outside, hot inside: Energy-saving forming of synthetic materials



Berlin, 11 February 2010

Innovation award for DBU funded project for
Dr.-Ing. Werner Neu Verfahrenstechnik in cooperation with TPS TechnoPartner Samtronic

Today, in Berlin, the company Dr. Neu Verfahrenstechnik from Altenstadt-Illereichen receives the Innovationspreis für Klima und Umwelt (IKU, innovation award for climate and environment), which the Bundesverband der Deutschen Industrie (BDI, Federal Association of German industry) and the Bundesministerium für Umwelt, Naturschutz und Reaktorsicherheit (BMU, Federal Ministry for the Environment, Nature Conservation and Nuclear Safety) co-tendered. The company accepts the award for its development for an energy-saving method to process synthetic materials from the hands of Dr. Werner Schnappauf, the Main Managing Director of the BDI. On the occasion of the award ceremony Norbert Röttgen, the Federal Minister for the Environment, Nature Conservation and Nuclear Safety, explains, "Since 1995 the company Dr. Neu has continuously pursued its aim to realise in practice its innovative and environmentally friendly concept." Dr. Fritz Brickwedde, the General Secretary of the Deutsche Bundesstiftung Umwelt (DBU, Federal Environment Foundation), which subsidised the process with a total of approximately 582,000 Euros, says, "I am delighted that this long-standing commitment is being acknowledged with this award today."

Melting, forming and cooling - for the production of firm plastic plates from synthetics granules extensive production technology but also huge amounts of energy are required. The thicker the synthetics parts will be for further processing, the longer is the time required for cooling. For many mass synthetics a temperature of approximately 220 degrees Celsius must be achieved in order to melt the granules fully. With the innovative method of the company Dr. Neu Verfahrenstechnik, however, only the surfaces of the synthetics granules need to be melted evenly. "Due to the subsequent heat exchange between the liquid surface and the cold core the so-called calorific mean temperature sets at about 100°C after a short period of time, so that a homogenous structure may be pressed irrespective of the thickness of the granule layer", explained Dr. Werner Neu, the Managing Director. It is essential that the forming of the melted mass happens immediately after the heat supply.

Thereby, the product line, which has been developed together with the plant construction company TPS TechnoPartner Samtronic from Göppingen and which consists of a melting reactor and a double belt press, is used. "The production process can be shortened significantly with this process", emphasises Voith, the Managing Director of TPS. And this will save energy - up to 50 percent in comparison to the common production processes. "A huge economic advantage", says Neu. In addition, the materials are protected due to the short heat supply. "The addition of stabilisators that are full of heavy metals can be reduced", Neu points out. Now that the method has already been tested successfully in practice, TPS already markets the technology globally.

DBU already supported the first experimental study relating to the innovative process as well as the development of a demonstration plant. "In Germany only we expect many potent users of this new technology. These result in an enormous potential relief of the strain on the environment", Brickwedde says. "The company outstandingly exemplifies how a small engineering office with its creative ideas can contribute greatly to the protection of our climate", says the DBU General Secretary. This process is already being developed further in the offices in Altenstadt-Illereichen and Göppingen. In the future it shall also be used for synthetic plates, which have a foam structure. The DBU contributes another 120,000 Euros.

DBU press release (German)